Method of molding and forming a switch device



y 1965 R. G. STEVENS 3,252,206

METHOD OF MOLDING AND FORMING A SWITCH DEVICE Filed July 9, 1962 .1.

[- 0 0 0 n n uLdnu F u a a n n C :j M I 7 Z s /20 7 [9,8 C 5 1217 20 INVENTOR. 13 Z TZ C17. 5 Zea/e72 United States Patent 3,252,206 METHOD OF MOLDING AND FORMING A SWITCH DEVICE Robert G. Stevens, Glen Ellyn, Ill., assignor to Molding Engineers, Inc., a corporation of Illinois Filed July 9, 1962, Ser. No. 208,445 3 Claims. (Cl. 29--155.55)

This invention relates to electrical controls, such as switch devices, and in particular, to methods of forming switch devices.

In one form of switch utilized in television tuner assemblies, an assembly is provided wherein a plurality of electrical switch contacts are carried on an insulated support, the switch contacts having connected thereto suitable terminals to which may be connected, as by soldering, tuning coils and the like. The present invention comprehends an improved method of forming the subassembly elements including the means defining the support, contacts, and terminals. Thus, a principal feature of the present invention is the provision of a new and improved method of forming a switch drive.

Another feature of the invention is the provision of such a method of forming a switch device including the steps of extending a plurality of electrical conductors in parallel, laterally spaced relationship, molding a plurality of supports of electrically insulating material about the plurality of conductors at longitudinally spaced positions, separating the conductors intermediate the supports to define a plurality of partially formed elements each comprising an insula-tive support having a plurality of conductors extending therethrough with the opposite ends of the conductors exposed at spaced portions of the support, and completing the forming of each element by forming the end of each conductor at one side of the support to define a plurality of electrical switch contacts, and forming the end of each conductor at the other side of the support to define a plurality of terminals for connection thereto of electrical conductors.

A further feature of the invention is the provision of such a method wherein the contacts are formed by bending one projecting end of each conductor arcuately back to a support.

A yet further feature of the invention is the provision of such a method wherein the terminals are formed at the opposite end of each conductor by bifurcating said opposite end.

Still another feature of the invention is the provision of a new and improved switch device.

Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawing wherein:

FIGURE 1 is a front elevation of a switch device such as may be formed by the method embodying the invention;

FIGURE 2 is an enlarged front elevation thereof;

FIGURE 3 is an end elevation thereof;

FIGURE 4 is a top plan view thereof;

FIGURE 5 is a top plan view illustrating one step in the method of forming the switch device;

FIGURE 6 is a top plan view illustrating a subsequent step in the forming of the switch device;

FIGURE 7 is an end elevation illustrating the step of FIGURE 6;

FIGURE 8 is atop plan view illustrating a final step in the method of forming a switch device; and

FIGURE 9 is an end elevation illustrating the step of FIGURE 8.

In the exemplary embodiment of the invention as disclosed in the drawing, a switch device element generally designated 10 is shown to comprise an elongated support 11 in which is molded a plurality of electrical conductors ,12 defining at one end a plurality of switch contacts 13 and at the opposite end a plurality of electrical terminals 14. The switch device element 10 may be utilized in applications, such as television tuner applications, wherein additional elements are associated therewith. The present invention, however, is directed to the subassembly switch device element illustrated in FIGURE 1 of the drawing and in an improved method of forming this subassembly element.

More specifically, the support 11 comprises an elongated support formed of a suitable electrically insulating material, such as an organic plastic. The conductors 12 comprise electrically conductive wires which may be coated as with silver, gold, etc. to provide improved electrical connection thereto. As best. seen in FIGURES 3 and 4, the wires 12 extend through the elongated plastic support 11 with the ends defining the contacts 13 projecting from one side 15 of the support, and the ends defining the terminals 14 projecting from a spaced portion of the support, herein the opposite side 16 of the support. The contacts 13 may be formed by suitable means such as by cold hardening, by welding of contact material to the wire ends, e-tc.; herein the contacts are formed in the wires 12 by an arcuate turning of the wire back toward the front side 15 of the support. The terminals 14 may be defined in the wires by a suitable forming process, such as by piercing, flattening, notching, rolling, etc.; herein the wires are bifurcated to define the terminals.

Referring now to FIGURES 5 through 9, the invention may be seen to comprise the method of forming the switch device element 10 including, as shown in FIGURE 5, a first step of extending a plurality of the wires 12 in parallel, laterally spaced relationship. The supports 11 are molded about the plurality of wires 12 at longitudinally spaced positions by suitable conventional molding apparatus (not shown). The wires 12 are then cut along transverse lines 17 intermediate the supports 11 to define a partially formed element 18, as shown in FIGURE 6, wherein the wires 12 extend through the support 11 and project substantially outwardly from the opposite sides 15 and 16 of the support.

As shown in FIGURE 6, the ends 12a of the wires 12 projecting from support side 15 are next engaged by a suitable forming die 19 which bends the wire ends 12a arcuately back to the support side 15 to define the contacts 13, as best seen in FIGURES 3 and 9.

Referring now to FIGURE 8, the final step of forming the elements 10 comprises the step of bifurcating the opposite ends 12b of the wires 12 by a suitable conventional splaying device 20. As shown in FIGURE 3, the bifurcated terminal 14 projects substantially from the support 11 for facilitated connection thereto of an electrical wire or the like.

In the illustrated embodiment, the support 11 includes a laterally enlarged upper portion 21 through which the wires 12 extend. A pair of recesses 22 and 23 may be provided in the support at the opposite sides thereof, which recesses partially overlap to define a through opening 24, as best seen in FIGURE 2, for use in mounting the switch device element. One hand of the support may be provided with an end boss 25 for use in carrying associated apparatus (not shown).

Thus, the invention comprehends an improved, simplified method of forming devices such as switch devices 10 wherein the electrical contacts 13 and terminals 14 are formed in electrically conductive wires molded in place in the supports 11. The process may be carried on continuously, as in the step illustrated in FIGURE 5. Apparatus for forming the wire ends to define the contacts 13 and terminals 14 may be of any suitable type well known to those skilled in the switch forming art, and requires no further description herein.

While I have shown and described certain embodiments of my invention, it is to be understood that it is capable of many modifications. Changes, therefore, in the construction and arrangement may be made without departing from the spirit and scope of the invention as defined in the appended claims.

I claim:

1. The method of forming a switch device comprising the steps of: extending a plurality of electrical conductors in parallel, laterally spaced relationship; molding a plurality of supports of electrically insulating material about said plurality of conductors at longitudinally spaced positions; separating the conductors intermediate said supports to define a plurality of partially formed elements each comprising an insulative support having a plurality of conductors extending therethrough with the opposite ends of the conductors projecting from spaced portions of the support; and completing the forming of each element by bending arcuately back to the support the projecting end of each conductor at one portion of the support to define a plurality of looped electrical switch contacts having one end embedded in the support and an opposite end arranged to engage and be supported by the exterior of said support.

2. The method of claim 1 wherein said step of forming the end of each conductor at the other spaced portion of the support comprises a step of splaying said end.

3. The method of claim 1 wherein said looped end is bent to have the distal portion thereof substantially perpendicular to the portion of the exterior of the support to which it is bent.

References Cited by the Examiner UNITED STATES PATENTS JOHN F. CAMPBELL, Primary Examiner.

BERNARD A. GILHEANY, WHITMORE A. WILTZ,

Examiners. 

1. THE METHOD OF FORMING A SWITCH DEVICE COMPRISING TORS IN PARALLEL, LATERALLY SPACED RELATIONSHIP; MOLDING A PLURALITY OF SUPPORTS OF ELECTRICALLY INSULATING MATERIAL ABOUT SAID PLURALITY OF CONDUCTORS AT LONGITUDINALLY SPACED POSITIONS; SEPARATING THE CONDUCTORS INTERMEDIATE SAID SUPPORTS TO DEFINE A PLURALITY OF PARTIALLY FORMED ELEMENTS EACH COMPRISING AN INSULATIVE SUPPORT HAVING A PLURALITY OF CONDUCTORS EXTENDING THERETHROUGH WITH THE OPPOSITE ENDS OF THE CONDUCTORS PROJECTING FROM SPACED PORTIONS OF THE SUPPORT; AND COMPLETING THE FORMING OF EACH ELEMENT BY BENDING ARCUATELY BACK TO THE SUPPORT THE PROJECTING END OF EACH CONDUCTOR AT ONE PORTION OF THE SUPPORT TO DEFINE A PLURALITY OF LOOPED ELECTRICAL SWITCH CONTACTS HAVING ONE END EMBEDDED IN THE SUPPORT AND AN OPPOSITE END ARRANGED TO ENGAGE AND BE SUPPORTED BY THE EXTERIOR OF SAID SUPPORT. 